Modular shell cabinet structure

ABSTRACT

Matching pan elements of sheet plastic having complemental hooked interlocking members and projection and socket registering members are assembled into hollow panel components. Such hollow panel components have coplanar pegs projecting from an edge and/or tenons of channel-shaped cross section projecting laterally beyond a side to engage in complemental sockets in another panel for assembling such panels into cabinet walls, shelves or drawers.

ghiiwfi States Patent 1 Bnpree [4 1 Feb. 20, 1973 [54] MODULAR SHELLCABINET [56l References Cited STRUCTURE UNITED STATES PATENTS [761Invent fla'ls'wemer Osnabrucke' 3,438,l64 4/1969 Duepree ..312/263Landstfasse 4331 GuterslOh- 3,307,504 3/1967 Cloyd 6! a1. ..l08/58 Aenwe d G y 3,325,585 6/l967 Brenncman ...52/262 l,l42,5l8 6/l9l5 Hinde...52/585 [221 3,160,120 l2/l964 Skubic ..I08/53 2 3,497,079 2/1970Kulweic ..52/620 x [21] App] No 8 3,543,462 12/1970 s am/3:61 ..52/264[30] Foreign Application Priority Data Primary Examiner-James T. McCallV V AztorneyRobert W. Beach Nov. 18, l969 Germany ..P 19 57 878.0

- [57] ABSTRACT Matching pan elements of sheet plastic having com- [52]"312/257 108/111 312/257 plemental hooked interlocking members andprojec- 312/257 SM, 52/262,52/585 tion and socket registering membersare assembled [51] Int. Cl. ....A47b 47/00 into hollow panel components,Such hollow panel V H components have coplanar pegs projecting from an[58] Field of Search ..312/257 R, 263, 111, 140, 257 g n /0r n n of chnnelh p cross secti n SK, projecting laterally beyond a side to engagein comple- 312/257 SM; 287/2092 E; 108/51, 58, 111; 52/619, 620, 621,585, 262, 264

mental sockets in another panel for assembling such panels into cabinetwalls, shelves or drawers.

8 Claims, 9 Drawing Figures PATENTED FEBZO I973 SHEET 5 OF 5 facturedreadily and accurately and assembled quickly and easily to produce thepanel structure.

A further object is to provide such structures utilizing a minimumamount of plastic material which, following assembly, are strong andrigid.

It is also an object to provide such components for shell cabinet workwhich, when assembled, will provide a construction attractive inappearance and of light weight.

Another object is to provide sheet plastic panels which can be assembledin different ways to provide different types of structures, eitherwithout modification or with minor modifications.

FIG. 1 is a perspective of matching pan elements in explodedrelationship, which can be assembled into a hollow panel, showing theinner sides of an upper interior pan element and of a lower exterior panelement.

FIG. 2 is a top perspective of an end portion of a somewhat modifiedlower pan element.

FIG. 3 is a top perspective of upper and lower sheet pan elementsassembled into a hollow panel, parts being broken away.

FIG. 4 is a top perspective of further modified interior and exteriormatching pan elements in exploded relationship.

FIG. 5 is a top perspective of an end portion of a hollow panel formedfrom pan elements similar to those shown in FIG. 4, but modified to someextent.

FIG. 6 is a plan of a drawer component fabricated from hollow panelsmade of assembled pan elements.

FIG. 7 is a fragmentary detail plan showing a portion of a drawerconstruction made of components differing from those shown in FIG. 6,such components being shown in exploded relationship.

FIG. 8 is a plan of a different type of drawer fabricated from hollowpanels, and FIG. 9 is a perspective showing fragments of componentpanels used in the construction of such drawer with the panel portionsdisposed in exploded relationship.

The hollow or shell panel components of the present invention can bemade from molded or extruded sheet plastic pan elements of differenttypes of construction. Such hollow panels are designed for assembly inthe manufacture of chests, desks and other types of fumiture, includingdrawers, and for built-in cabinets including shelves. The interior ofthe pan elements making up each hollow panel are stiffened interiorly byfeathers so that when they are assembled they will present a smoothexterior but will be strong and rigid, although light in weight.

The individual pan elements can be molded or extruded depending upontheir design and have projections and sockets which can be interfittedto locate the pan elements in matching registry and to secure the panelements permanently together to form the hollow or shell panels. Suchpanels also have projections and sockets to enable them to be assembledin coplanar relationship or perpendicular to each other depending uponthe type of structure to be fabricated.

A modular building panel unit can be fabricated by assembling theexterior pan element 1 and the interior pan element 2 shown in FIG. 1.These matching elements are assembled in the relationship shown withtheir depressed sides facing each other. When assembled, such depressedsides will be on the interior of the panel, so that the exterior surfaceof the resulting hollow panel or shell will be smooth.

The exterior pan element 1 includes the sheet wall 3 having tenons 4projecting at right angles from opposite end portions of such wall. Suchtenons are preferably of channel-shaped cross section and are of alength to project laterally beyond a surface of the assembled panel.

End flanges 6 projecting inwardly from the wall are of sufficient widthto close the opposite ends of the interior panel hollow when the pansections 1 and 2 are assembled. Side comer flange sections 7 joined tothe end flanges 6 extend along the sides distances at least equal to thewidth of the tenons 4. Such end and corner flanges also assist inrigidifying the opposite ends of the pan 1 and the resulting panel.

Hooked lock-joint fingers 8 project inwardly from the inner surface ofthe wall 3 a distance less than the thickness of the panel. Preferablythese fingers are arranged in two rows extending lengthwise of the pan1, and their root portions are connected together by fins 8'. Betweenadjacent lock-joint fingers 8 stump sockets 9 project from the innersurface of the sheet wall 3 alongside the finger-joining fins 8'. Thefingers 8 and intervening fins 8 constitute strenghthening andrigidifying feathers, and additional intermediate feathers forstrengthening and rigidifying purposes may be disposed between suchfeathers. These intermediate feathers are shown as spaced parallel fins10 also projecting from the inner surface of the sheet wall 3.

The interior pan element 2 also includes a sheet wall 11. Side flanges12 extend along opposite longitudinal edges of the wall 11 in positionssuch that their free edges abut the corresponding edges of wall 3 of pan1, or lie alongside such edges of the wall 3 when the pans are assembledinto a panel with their depressed sides facing each other. The width ofeach side flange should therefore be approximately equal to thethickness of the hollow panel. The combination of the sheet wall 11 andthe two side flanges 12 provides a pan section of channel-shaped crosssection.

From the interior side of wall 11 inwardly from flanges 12 hookedlock-joint fingers 13 project which are located in positionscorresponding to the locations of the hooked lock-joint fingers 8 ofpan 1. Such fingers are formed complementally to the fingers 8 and areproportioned so that when the two pan elements are assembled the hookedportions of such fingers will interengage in locking relationship.

In addition, pegs 14, which may be hollow or solid, project from theinterior surface of the wall 11 in positions registering with thesockets 9 projecting from the interior of wall 3. Such pegs are of asize to fit snugly into the sockets for locating the pan elementsaccurately relative to each other and preventing relative edgewisesliding of the pans after they have been engaged in assembledrelationship.

The edge flanges 12 of the interior pan 2 constitute strengthening andstiffening feathers for the wall 11, and additional feathers may beprovided for further stiffening if desired. Thus, the hooked latchfingers 13' arranged in one row lengthwise of the pan can be carried orjoined by a fin 13". In addition, intermediate ribs 15 can extendlongitudinally of the pan element 2 in position either to be disposed inregistry with or offset from the fins of the pan element 1 when the panelements are assembled. One or more additional fins a extendinglongitudinally of the pan element 2 may be provided if desired at anysuitable location or locations.

The interior pan element 2 preferably is sufficiently shorter than theexterior pan element 1 so that the pan element 2 will fit between thetenons 4 upstanding from the opposite end portions of the exterior panelement 1 when the pan elements are assembled. Alternatively, theopposite ends of the wall 11 of the interior pan element 2 can benotched at locations necessary to fitaround such tenons. If the tenonsare of channelshaped cross section such notches need only be of a widthand depth to receive the flanges of the tenons.

When the complemental pan elements 1 and 2 have been disposed inmatching positions during assembly, the pegs 14 will slide into theirrespective stump sockets 9 to guide the pans accurately into their finalassembled relationship. Continued approach movement of the pans willcause the hooks of the lock-joint elements 8 and 13 first to deflectwedgingly and then to snap into interlocking relationship to secure thepans positively against subsequent separation.

Alternatively, registration of the two pan elements can be accomplishedby interfitting of the pegs 14 and stump sockets 9 and the pans could besecured together by adhesively bonding the edges of fins 10 and ribs 15,if they are disposed in registry, and the edges of flanges 12 and thecorresponding edges of sheet wall 3 in abutting relationship. Suchbonding procedure would eliminate the need for the interlocking elements8 and 13. For bonding the two pan sections together any suitableadhesive can be employed, but setting of the adhesive can be expeditedby applying thermosetting adhesive to contacting parts and acceleratingsetting of the adhesive by placing the panel in a dielectric,highfrequency field.

Panels resulting from the assembly of exterior pans 1 and interior pans2 shown in FIG. 1 are adapted for assembly with other hollow panelsdisposed perpendicular to such resulting panels. Such panels can beconnected by the tenons 4 fitting in complementalsockets. The end of apanel extending perpendicular to the panel formed by assembly of the panelements 1 and 2 would cover any gap between an end flange 6 of the panelement 1 and the adjacent end of the sheet wall 11 of pan element 2. Insome instances, however, it may be desirable to assemble the resultinghollow panels in 'end-to-end relationship, such as, for example, inmaking shelves. For such use the tenons 4 can be omitted and the sheetwall 11 can be made long enough to extend throughout the length of thepanel between end walls 6. In such instance the end portions of the sideflanges 12 of pan 2 would overlap the side corner flanges 7 of pan 1 orbe cut out to abut such side comer flanges. In either case the interiorhollow of the resulting panel would be completely enclosed.

In order to join hollow panels in end-abutting relationship, projectionsin the form of cantilever dowels or pegs 5 may project lengthwise fromthe end flanges 6, and such dowels may be either smooth or barbed. Thebarbed dowels of FIG. 2 are shown as having annular serrations orthreads. Such pegs or dowels may fit into' complemental sockets havingsmooth bores, and the dowels can be secured in such sockets eithersimply by friction of the serrations or barbs or the dowels may bebonded in the sockets by suitable adhesive. Even where panels are to bejointed in end-to-end relationship, laterally projecting tenons may beprovided to enable an additional panel or panels to be assembled inperpendicular relationship to the panels assembled in coplanarrelationship.

In FIG. 3 a hollow panel is shown of a construction suitable forassembling in perpendicular relationship to a hollow panel formed byassembling the two pans l and 2 of FIG. 1. Such panel is formed byassembling the exterior pan element 1a and the interior pan element 2awith their depressed sides disposed in face-to-face relationship. Theexterior pan element 1a has a plurality of parallel strengthening andrigidifying feathers extending lengthwise of it, including side flanges12a of a width equal to the thickness of the finished hollow panel. Twoparallel fins 15a are shown extending lengthwise of the central portionof the exterior pan 1a in parallel relationship. The edge of each ofthese fins has a rabbet for receiving an edge portion 17 of acomplemental fin 10a projecting inward from the sheet wall of theinterior pan element 2a.

In addition, the edge portion of one or move deep fins 18 projectinginward from the sheet wall of the interior pan element 2a may be engagedin the groove formed between ribs 19 projecting inwardly from theinterior of the sheet wall of exterior pan elements la. Also the edgesof side flanges 12a may be formed with rabbets having grooves 20 intowhich narrow edge flanges of the sheet wall of interior pan element 2amay fit. The complemental feather elements of the two pans which areinterfitted can be bonded together to secure such pans permanently intheir assembled relationship.

When the interengaged edges of the complemental feather elementsprojecting inwardly from the sheet walls of the pan 1a and 2a have beenbonded together, a very strong and rigid shell panel results which stillis very light. Moreover, the two pan sections are secured togethersufficiently strongly so that they cannot be separated even by quitelarge interior prying forces. Consequently, it is practical to connectan end portion of the hollow panel shown in FIG. 3 by inserting snuglyinto the ends of the elongated socket recesses formed within itconnecting members such as the tenons 4,

shown in FIG. 1. To enable such a connection to be made, the feathersextending from the sheet walls into the interior hollow of the panelshould be located so that they will not conflict with entrance of thetenons 4' into recesses between feathers but will form sockets locatedin positions corresponding to the tenons 4 shown in FIG. 1.

Specifically, a comparison of FIGS. 1 and 3 will show that the nearertenons 4 in FIG. 1 are located at the edge of the panel, and the recessat the left of FIG. 3 is located at the edge of the panel. The tenonsfarther away in FIG. 1 are spaced from the opposite edge of the paneland they are wider than the nearer tenons. Their location and widthmatch the location and width of the recess near the right side of thepanel shown in FIG. 3 which is spaced from the right flange 12a.

In addition, in most cases it is desirable for the tenons 4 to becapable of being locked into their sockets. For this purpose serrations22, which preferably are undercut to form barbs, are provided on onesurface of each tenon 4. Complemental serrations 22a are formed in therecesses of the panel shown in FIG. 3. Actually, such serrations areformed on opposite sides of the recess so that the panel of FIG. 3 canbe fitted on and locked to the tenons 4 at either end of the panelformed by assembly of the pan sections shown in FIG. 1. The panels thusassembled are tightly and permanently secured together to form a strong,rigid and light panel assembly. The interengaged tenons and recesses aresufiiciently resilient so that a tight fit can be provided between themto minimize relative movement between the parts when they are assembled.

In FIG. 4 a modified type of shell panel construction is illustrated,including a plate or pan section lb, which does not have edge flanges,and a pan section 2b which has flanges 6a on opposite ends and flanges12a on opposite sides. The exterior pan element 1b has stump sockets 9,as described in connection with FIG. 1, for receiving socket-engagingpegs carried by the inner side of the interior pan 2b to accomplishregistration of the two pan elements for assembly. In this structure thefeathers on the exterior pan section lb include fins 10b joined by a web23 recessed inward from the sheet wall 3a to provide a wide outwardlyopening groove between the fins. The interior pan element sheet wall 110is formed with an outwardly opening narrow groove 24 located adjacent toand parallel to one edge of the pan.

In this instance the tenons 4a are carried by and projected inward fromthe interior pan sheet wall 11a instead of being carried by the exteriorpan section as in the construction of FIG. 1. These tenons can be moldedintegrally with the pan sheet wall or can be formed separately andsubsequently bonded to the wall, as may be preferred.

FIG. 6 illustrates the manner in which shell panels formed from the panelements 1b and 2b of FIG. 4 can be incorporated in a drawer componentof a cabinet. The sides are formed of shell panels 1b, 2b, formed asshown in FIG. 4. The tenons 4a of these panels can be received inrecesses in front and back shell panels 25 constructed as shown in FIG.3. The only difference between the drawer front and drawer back of FIG.6 and the hollow panel of FIG. 3 is the provision of an external groove24a in the sheet wall of pan 2a between the ribs 19 closer to the edgerib or flange 21 and such edge rib. This groove is spaced from the outerface of the corresponding edge flange 12a a distance equal to thespacing between the groove 24 in pan 2b shown in FIG. 4 and the paneledge, and the width of such groove is equal to the width of groove 24.

When the shell panels 1b, 2b and the shell panels 25 are assembled inthe relationship shown in FIG. 6 to form the sides, front and back of adrawer, such panels would all be oriented so that the grooves 24 and 24aface inwardly and are in registry. Before the tenons 4a are insertedinto the recesses of the panels 25 a drawer bottom board 26 is disposedwithin the drawer frame, and the front and back panels 25 are movedtoward each other until the corresponding edges of the drawer bottom arefitted into the grooves 24a of such panels.

When the front and back panels have thus been assembled with the drawerbottom, the drawer, sides lb,

2b are moved toward the drawer bottom and front and black panels, andthe tenons 4a are inserted into recesses in such front and back panels.As these tenons are moved fully into their sockets, the opposite edgesof the drawer bottom 26 will be received in the grooves 24 of the sidepanels. Such engagement of the edges of drawer bottom 26 in the grooves24 and 24a of the drawer frame walls will secure the drawer bottomfirmly in place.

The grooves formed between the fins 10b and the webs 23 of the sidepanels lb, 2b, shown in FIG. 4, will open outwardly in the oppositesides of the drawer assembly, as indicated in FIG. 6. In mounting thedrawer guide strips or runners can be provided on the opposite sides ofthe drawer-receiving opening to fit into such opposite grooves forsupporting and guiding the drawer for sliding movement. construction InFIG. 7 an alternative type of drawer frame corner construction is shownemploying the type of panel connection shown in FIG. 2. In this instancethe drawer sides can be formed of shell panels 1,2 having structure suchas shown in FIGS. 1 and 2. The other drawer wall panels 27 can be of anysuitable solid or shell construction and have in their opposite endportions sockets 28 located appropriately to receive the cantileverdowels or pegs 5 projecting endwise from the end of panels 1,2. It is,of course, evident that pegs 5 will be shorter than the thickness ofpanels 27 so that the ends of panels 1,2 can abut the adjacent sides ofthe panels 27 in each instance.

While the panels 27 can be of shell construction as mentioned above,these panels alternatively can be wooden boards or can be plywood orparticle board faced with a finishing sheet of veneer. In suchconstruction the sockets 28 for pegs 5 can simply be blind holes boredin the inner side of the panel. Grooves 24b in panels 1,2 and grooves240 in panels 27 will be provided to receive the margins of a drawerbottom.

FIGS. 8 and 9 show another type of drawer construction in whichpartitions are provided. The drawer front and the drawer back are madeof shell panels 1,2, assembled from components such as shown in FIG. 1,for example. Side sections of the drawer frame can be formed from shellpanels 25a, similar to the panels 25 shown in FIG. 6, having a structuresimilar to the panel of FIG. 3. The partitions are formed by shellpanels 1c,2c the structure of which is similar to the panel of FIG. 4,except that the web 23 is omitted from the exterior pan lb and the panelside wall is continuous. Tenons 4a project from one side of the panelend, and similar tenons 4b project from the opposite side of the panelend. These tenons can then be received in corresponding sockets in. theends of panels 25a abutting the opposite sides of the panels 10,20.

Alternatively, an end of a panel 25a can be constructed as shown in FIG.5, in which tenons 4a project laterally from the panel at any locationwhere a partition is desired. The drawer slides can be made as long asnecessary, or can be made in more than one part joined by pegs a beinginserted in sockets in the end of a coplanar panel section. The tenons4a are molded integrally with the pan sheet wall, or can be bonded tosuch wall at any desired location.

In a partitioned drawer structure such as shown in FIG. 8 a separatebottom board 260 may be provided for each compartment. Alternatively,each partition panel 1c,2c can be made sufficiently narrower than thedrawer frame panels so as to clear the bottom. In that instance a singlebottom panel extending over the entire area of the drawer can be securedin place by its margins being received in inwardly opening grooves inthe frame panels.

Modular shell panels for cabinet construction, and particularly formaking drawers, can be provided in only a few standard widths, such, forexample, as 40, 50 and 60 centimeters. Drawers of corresponding depthcan be constructed from such panels which will meet most requirements.The side panels can also be made either in standard lengths or,particularly for a shell panel such as shown in FIG. 3, can be made ofindeterminate length and simply cut off to the particular lengthdesired. Consequently, components of a few types can easily be outaccording to the requirements of a considerable variety of structures.The shell panel components can be assembled quickly with unskilled laborand without requiring tools except for cutting the panels to the desiredlength in appropriate instances. It is therefore possible to constructdrawers and other cabinet components from shell panels according to thepresent invention much more economically than constructing conventionaldrawers and cabinet parts while atthe same time providing a constructionof extraordinarily high quality, rigidity and precision, which is verylight.

I claim:

1. A modular shell component for use in cabinet structures comprising ahallow panel including two sheet wall elements and means connecting saidsheet wall elements in parallel spaced relationship, a projection havingits root integral with one of said sheet wall elements and locatedadjacent to an edge thereof for reception in a socket of an adjacentpanel, and a flange projecting from one of said sheet wall elementstoward I the other of said sheet wall elements for closing the spacebetween said sheet wall elements along said edge of said sheet wallelement adjacent to said projection.

2. The shell component defined in claim 1, in which the projectionprojects transversely of the sheet wall elements from the inner face ofthe sheet wall element with which its root is integral, and theprojection is of a length greater than the spacing between the sheetwall.

elements.

3. The shell component defined in claim 1, in which the projectionprojects transversely of the sheet wall' elements from the outer side ofthe sheet wall element with which its root is integral.

'4. The shell component defined in claim 1, in which the root of theprojection is integral with the outer face of the flange, and theprojection projects therefrom substantially parallel to the planes ofthe sheet wall elements.

5. The modular shell component defined in claim I, in which the hollowpanel has projections projecting generally coplanar of the panel from anedge thereof, and pro ections pro ecting laterally beyon one sidereceiving the projection therein, for holding an edge of 7 said secondhollow panel in abutment with a side outer face of the first hollowpanel with the two panels in substantially mutually perpendicularrelationship.

8. A cabinet structure comprising a first hollow panel including twosheet wall elements and means connecting said sheet wall elements inparallel spaced relationship, a projection having its root integral withone of said sheet wall elements and located adjacent to an edge thereof,and a second hollow panel including two sheet wall elements and meansconnecting said sheet wall elements of said second hollow panel inspaced parallel relationship, defining a socket complemental to saidprojection, opening lengthwise through an edge of said second hollowpanel and receiving said projection therein, for holding an edge of saidsecond hollow panel in abutment with a side outer face of said firsthollow panel with said two panels in substantially mutuallyperpendicular relationship.

1. A modular shell component for use in cabinet structures comprising ahallow panel including two sheet wall elements and means connecting saidsheEt wall elements in parallel spaced relationship, a projection havingits root integral with one of said sheet wall elements and locatedadjacent to an edge thereof for reception in a socket of an adjacentpanel, and a flange projecting from one of said sheet wall elementstoward the other of said sheet wall elements for closing the spacebetween said sheet wall elements along said edge of said sheet wallelement adjacent to said projection.
 1. A modular shell component foruse in cabinet structures comprising a hallow panel including two sheetwall elements and means connecting said sheEt wall elements in parallelspaced relationship, a projection having its root integral with one ofsaid sheet wall elements and located adjacent to an edge thereof forreception in a socket of an adjacent panel, and a flange projecting fromone of said sheet wall elements toward the other of said sheet wallelements for closing the space between said sheet wall elements alongsaid edge of said sheet wall element adjacent to said projection.
 2. Theshell component defined in claim 1, in which the projection projectstransversely of the sheet wall elements from the inner face of the sheetwall element with which its root is integral, and the projection is of alength greater than the spacing between the sheet wall elements.
 3. Theshell component defined in claim 1, in which the projection projectstransversely of the sheet wall elements from the outer side of the sheetwall element with which its root is integral.
 4. The shell componentdefined in claim 1, in which the root of the projection is integral withthe outer face of the flange, and the projection projects therefromsubstantially parallel to the planes of the sheet wall elements.
 5. Themodular shell component defined in claim 1, in which the hollow panelhas projections projecting generally coplanar of the panel from an edgethereof, and projections projecting laterally beyond one side thereof.6. The modular shell component defined in claim 1, in which theprojections are molded integrally with one of the sheet wall elements.7. A cabinet structure comprising the shell component defined in claim1, and a second hollow panel including two sheet wall elements and meansconnecting said sheet wall elements of said second hollow panel inspaced parallel relationship, defining a socket complemental to theprojection, opening lengthwise through an edge of said second hollowpanel and receiving the projection therein, for holding an edge of saidsecond hollow panel in abutment with a side outer face of the firsthollow panel with the two panels in substantially mutually perpendicularrelationship.